Stackable container with air cell corner assembly and associated container blank

ABSTRACT

A tray-type container includes a bottom wall, longitudinally-extending outer side walls, and laterally-extending end walls, the outer side walls and the end walls extending upwardly from the bottom wall to form an inner cavity. The container includes a corner assembly configured to increase the container stability. The corner assembly includes an arrangement of corner panels configured to form air cells that extend across the end of the container and serve to provide added stability to the container. The containers may be used singularly, or a plurality of tray-type containers may be unitized in several stacked configurations. Typically, the plurality of unitized containers are placed upon a shipping pallet or slip sheet, or placed within a shipping container to facilitate shipping by large carriers.

FIELD OF THE INVENTION

This invention relates generally to shipping and display type containers having angled corner panels.

BACKGROUND OF THE INVENTION

Cartons or containers formed from folded corrugated paperboard or similar flat sheet stock material are often stacked on one another during shipping and storage of products. In high volume retail stores, product is not only stored in stacked cartons, but frequently is presented to consumers in that form, e.g., with the stacked cartons disposed on pallets. Stacking is obviously efficient as to the use of space and pallets enable a number of cartons to be handled as a unit.

Containers in stacks are subjected to various forces, not limited to vertical compression due to the weight of containers over them in a stack. Such forces (as well as vertical compressive forces) are aggravated by handling, for example transport of a stack on a pallet, manual handling of one or more containers in a stack, etc. Tension and/or compression applied in various directions to the container walls can be sufficient to wholly or partly collapse a container or laterally to deflect, bend or fold the vertically oriented walls of the container. The result is a reduction of structural integrity, and may include crushing or other damage to the container contents. In addition, when the walls of one or more containers in a stack are crushed, wholly or partly collapsed, or otherwise deformed, the deformed container may no longer provide a stable horizontal support for containers stacked over it. The overlying stack may then tip laterally. A leaning “tower” of containers may fall, and even if there is no injury to persons, the contents of the containers may spill or be damaged.

Apart from instability due to partial collapse of the walls of one or more containers in a stack, instability leading to spills and possible collapse of a stack may be caused by containers being shifted horizontally relative to underlying containers. Customer access and traffic in retail/warehouse stores makes it likely that containers will be shifted horizontally.

It often is necessary for stock clerks at the warehouse retailer to rearrange containers on a pallet as certain containers are emptied, for example to consolidate product from a number of nearly empty open cartons into one, to restack or reposition the cartons for neatness, etc. It is advantageous if such rearrangement can be accomplished easily and quickly, especially because stock clerk staffing at warehouse retailers is preferably minimal. Containers stacked on a pallet, however, may be difficult to maneuver easily or quickly, may be stacked in close proximity to each other and may be bulky and cumbersome when filled with merchandise. If containers are stacked on open containers, which is sometimes desirable, the stack may have inadequate support.

SUMMARY OF THE INVENTION

In accordance with aspects of the present invention, a single piece blank for forming a container with improved stacking stability is provided. The blank includes a bottom panel, and an end panel hingedly connected to the bottom panel by a first fold line. The blank also includes an outer side panel having an outer edge and hingedly connected to the bottom panel by a second fold line. An inner side wall panel is hingedly connected to the outer panel. The blank further includes and air cell shaped corner assembly including a first corner panel, a second corner panel, a third corner panel and a forth corner panel. Still further, an end panel flap is connected with the end panel via an interrupted and spaced apart number of hinge flaps.

In accordance with another aspect of the present invention, a container includes a bottom panel, and outer side panels that extend upwardly from the bottom panel. The container also includes end panels that extend upwardly from the bottom wall to form, along with the side panels, an inner cavity. The container further includes a corner assembly configured to form air cells that extend across an end of the container. The corner assembly includes a first corner panel and a third corner panel positioned parallel the end panel, but separated by the second corner panel. Additionally, the corner assembly includes a forth corner panel positioned parallel to and affixed to the outer side panel. An end panel flap is also positioned substantially parallel to and engaging with the first corner panel and second corner panel.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.

FIG. 1 is a perspective view of a container blank formed in accordance with the present invention;

FIG. 2 is a perspective view of a partially erected container formed from the blank of FIG. 1;

FIG. 3 is another perspective view of a partially erected container formed from the blank of FIG. 1;

FIG. 4 is yet another perspective view of a partially erected container formed from the blank of FIG. 1; and,

FIG. 5 is a perspective view of a container made from the blank of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention includes a single sheet of foldable material cut and scored to form a blank formable into a container having angled corner walls. By way of overview and with reference to FIGS. 1-5, an embodiment of the present invention includes a single piece blank 20 arranged to form a stackable container 50. Specific details of the blank 20 and container 50 are described with more particularity below.

The present invention will now be described with reference to the accompanying FIGS. 1-5 where like numerals correspond to like elements. In all FIGURES, cut lines are shown as solid lines, score lines or lines of weakness are shown as broken lines. The present invention is directed to a tray-type container that utilizes a corner assembly having an angled corner panel coupled with other corner panels to create a modular stackable container. The container includes an arrangement of panels, which are adapted to provide suitable container stability.

One suitable embodiment of the blank 20, constructed in accordance with the present invention is illustrated in FIGS. 1 and 5. The blank 20 and container 50 include a bottom panel 20, longitudinally-extending outer side walls 26, and laterally-extending end walls 24. A plurality of tray-type containers 50 may be placed upon a shipping pallet or slip sheet (not shown), or placed within a shipping container (not shown) to facilitate shipping or displaying at a retail location.

For the purpose of further description herein, the downward direction is defined as the direction perpendicular to bottom panel 22 that corresponds to the outer surface of the bottom panel when the container 50 has been erected, and the upward direction is defined as the direction perpendicular to the bottom panel that corresponds to the inner surface of the bottom panel when the container 50 has been erected.

The blank 20 and resulting container 50 is typically made from any suitable material used in the shipping, storing or displaying of goods. Suitable, nonlimiting examples of such materials include paperboard, containerboard, cardboard, pasteboard, fiberboard, corrugated containerboard, corrugated paperboard, single wall corrugated containerboard, multiwall corrugated containerboard or a combination thereof. As best shown in FIG. 1, a blank 20 is stamped out of any of these suitable materials and assembled in a manner which can be seen in FIGS. 1-5.

With continued reference to FIG. 1, the blank 20 includes a bottom panel 22 of generally rectangular shape having multiple edges. It will be appreciated, however, that the bottom panel 22 may also be of other geometries, such as, without limitation, square. Unless otherwise apparent, the term “edges” refers generally to a zone or line of weakness along which a part can be folded, such as a score line, or a cut line. Opposite outer side wall panels 26 are hingedly connected to opposite side edges of the bottom panel 22 along fold lines 21. The blank 20 further includes end panels 24, which are hingedly connected to the remaining two opposite edges of the bottom panel 22 along fold lines 23. The outer side panels 26 include inner side panels 28, which are hingedly connected to the outer side panels 26, along a fold line 33, opposite the bottom panel 22.

Further, the outer side panels 26 include air cell corner assemblies 46 located at opposite ends of outer side wall panels 26, and are hingedly connected to the outer side panels 26 along fold lines 27. The fold lines 27 are substantially perpendicular to fold lines 21. The corner assemblies 46 include a first corner panel 30 connected with the outer side panel 26 along fold line 27. A second corner panel 32 is connected with the first corner panel 30 along fold line 29, opposite fold line 27. A third corner panel 34 is connected with the second corner panel 32 along fold line 31, opposite fold line 29. Still further, a third corner panel 48 is connected with the third corner panel 34 along a fold line 33. The first corner panel 30 and the second corner panel 32 each include a hinge flap notch 38. The hinge flap notch 38 is typically formed in an edge that lies substantially perpendicular to fold lines 27, 29, and 31. Additionally, the third corner panel 34 includes a locking tab slot 40. The locking tab slot 40 is generally formed in the third corner panel 34, adjacent or along fold line 31. Those skilled in the art will appreciate the locking tab slot 40 is designed to work in tandem with the locking tabs 44 (discussed below) in order to help hold the container 50 in an erect state.

With regards to relative size, the first corner panel 30 and the third corner panel 34 are substantially equal is geometry and size. Also, the second corner panel 32 and the forth corner panel 36 are substantially equal is geometry and size. However, the second corner panel 32 and the forth corner panel 36 are sized smaller than the first corner panel 30 and the third corner panel 34. The ratio of size of the second corner panel 32 and the forth corner panel 36 relative to the first corner panel 30 and the third corner panel 34 is variable, and is within the skill of those in the art to determine. Such factors that may affect the ratio size includes the nature of product (not shown) placed within the container 50, or the desired air cell size.

The end panels 24 include end panel flaps 36, which are hingedly attached to the end panel 24, opposite the bottom panel 22, by hinge flaps 42 along interrupted cut line 31. As depicted in the FIGURES, only two hinge flaps 42 are used, however, it will be appreciated that the present invention may include more or fewer hinge flaps 42 without exceeding the spirit and scope of the present invention. It will also be appreciated that as the hinge flap notch 38 (discussed in more detail below) is configured to receive the hinge flaps 42, if more or fewer hinge flaps 42 are used, then the hinge flap notch configuration will need to change accordingly. Positioned on an outer edge of the end panel flaps 36 are locking tabs 40. Those skilled in that art will appreciate that the locking tabs 40 and the locking tab slot 44 are configured to interact upon formation of the container 50 (discussed in more detail below), to lock the container 50 in its assembled form.

Referring now to FIGS. 2-5, one method of constructing the container 50 from the blank 20 will be described. In the ensuing description, erecting one side of the containers will be described. However, it will be appreciated that the other side of the container is formed in substantially similar steps.

The first step may begin with the inner side panel 28 being folded inwardly, about fold line 33, approximately 180° such that the inner side panel 28 and the outer side panel 26 lie adjacent one another and in parallel planes. Additionally, both the second corner panel 32, the third corner panel 34 and the forth corner panel 48 are folded inwardly, about fold lines 29 and 31, such that the third corner panel 32 and the first corner panel 30 lie in parallel planes, separated in distance from one another by the second corner panel 32. Subsequently, the forth corner panel 48 is folded about fold line 33 to bring the forth corner panel adjacent a portion of the outer side wall 26. At this point, the outer side wall 26 and the forth corner panel 48 may be suitably attached to one another, via, an adhesive, tape, or mechanical fastener. Likewise, the first corner panel and the second corner panel may also be attached to one another in a similar fashion. At this stage, the corner assemblies 46 form air cells 52, defined by the first corner panel 30, second corner panel 32, and third corner panel 34. FIGS. 2 and 3, best represent the container at this stage of formation.

With specific reference to FIGS. 3 and 4, additional stages of container formation are depicted. Specifically, the entire wall panel and corner assembly 46 is folded upwardly along fold line 21 such that the first corner panel 30 and the second corner panel 32 lie in a plane parallel to fold line 23. At this stage of formation, the outer side wall 26, inner side wall 28 at in a plane that is approximately 90° relative to the bottom panel 22. Likewise, the corner assemblies 46 are formed into air cells 52 and extend across the ends of the container 50, between the respective side outer side panels 26.

Further, end panels 24 are then folded upright, along fold line 23, approximately 90° with respect to the bottom wall panel 22, as best shown in FIG. 4. In this position, the hinge flap notches 38 are along an upper edge of the end walls of the container 50 are spatially positioned to receive hinge flaps 42 when the end panel flap 36 if folded over the first corner panel 30 and the second corner panel 32 as depicted in FIG. 5. The locking tabs 44 may then be inserted into the locking tab slots 40 to help hold the container 50 in an erect position.

In use, container 50 may be filled with product (not shown) and stacked with one or more other containers 50 on a pallet (not shown) or display shelf (not shown). In one possible application, a selected number of containers 50 filled with product (not shown) are stacked on pallet (not shown), and pallet (not shown) may be moved from receiving directly to the display floor of the retailer (perhaps after removing an external common cover, strapping or wrap), where end-user purchasers have access to the pallet of containers. The individual containers 50 may not include covers, tops or lids of corrugated material, instead being arranged such that the upper containers engage over and cover the next lower one. The containers 50 are accessed on the display floor and generate less waste. Purchasers may select product (not shown) from one of the open containers 50, generally from those containers at the top of the stack. The increased strength of the containers allows the containers to better resist vertical collapse or lateral deflection caused by the forces of handling and the like. Handholds (not shown) allow containers to be easily manipulated by stock personnel or others, individually or in stacks of two or more.

As another alternative, the container of the invention may also include a top or other means to cover the container. In addition to the advantages apparent from the foregoing description, the present invention improves the container's strength, especially crushed in the vertical direction. A related advantage is that the contents of such containers are less likely to be damaged.

While an embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. For example, the blank may also include other features specified by the customer, such as hand holds, vent holes, grease or moisture barriers and the like without exceeding the scope of the present invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow. 

1. A blank for a container comprising: a single sheet of foldable material cut and scored to define a bottom panel, said bottom panel having a side edge and an end edge; a sidewall panel hingedly attached to said bottom panel along said side edge, said sidewall panel having a front edge, a first corner panel hingedly attached to said side panel along said front edge; a second corner panel hingedly attached to said first corner panel, opposite said side panel; an third corner panel hingedly attached to said second corner panel, opposite said first corner panel; a forth corner panel hingedly attached to said third corner panel, opposite said second corner panel, an end panel hingedly attached to said bottom panel along said end edge; and end panel flap hingedly attached to said end panel along a spaced apart hinge line, opposite said bottom panel, wherein the first corner panel and the third corner panel are substantially equally sized.
 2. The blank of claim 1 wherein the blank is formed from at least one of a paperboard, containerboard, cardboard, pasteboard, fiberboard, corrugated containerboard, corrugated paperboard, single wall corrugated containerboard, and multiwall corrugated containerboard.
 3. The blank of claim 1 further comprising an inner sidewall panel hingedly attached to said outer sidewall panel, opposite said bottom panel.
 4. The blank of claim 1 further comprising first a hinge flap notch formed in an outer edge of said first corner panel.
 5. The blank of claim 1, wherein said forth corner panel further comprises a locking tab slot.
 6. A container comprising: a bottom panel, a side panel extending upwardly from said bottom panel; an end panel extending upwardly from said bottom panel to form, along with said side panel, an inner cavity; a first corner panel adjacent the end panel; a second corner panel positioned perpendicular to the first corner panel; a third corner panel positioned parallel to the first corner panel, and spaced apart from the first corner panel by the second corner panel; a forth corner panel extending connected with the third corner panel, the for the corner panel positioned parallel the side panel. and, an end panel flap positioned adjacent the third corner panel.
 7. The container of claim 6 wherein the container is formed from at least one of a paperboard, containerboard, cardboard, pasteboard, fiberboard, corrugated containerboard, corrugated paperboard, single wall corrugated containerboard, and multiwall corrugated containerboard.
 8. The container of claim 6, wherein said forth corner panel further comprises a locking tab slot. 